Electrical drilling



21 9-121 :MiROS Get. 26, 1965 J, P. FORD ELECTRICAL DRILLING 2' Sheets-Sheet 1 INVENTOR.

JOHN 2 FORD G. In

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' mus Filed March 28, 1963 Get. 25, 1965 J. P. FORD v ELECTRICAL DRILLING Filed March 28, 1963 2 Sheets-Sheet 2 INVENTOR P. FORD fwm magma JOHN ATTORNEY iinited sates ha tens 3,214,563 ELECTRICAL DRlLLING John P. Ford, {Ianoga Park, Chili, assignor to North American Aviation, Inc. Filed Mar. 28, 1963, Ser. No. 268,642 4 Claims. (Cl. 219-69) This invention relates to a method and apparatus'for electrical machining. More particularly the invention pertains to a method and apparatus for electrical machining wherein the accuracy is controlled through the use of alaser.

The electric arc has been widely used for the drillling and cutting of materials. Simply stated, this is accomplished by the evaporation of the material due to'the large work energies of the arc. In drilling with the use of an electric arc, the size'of the hole and-its depth in theconducting material which is being worked-can becontroll'ed by the current .fiowing in the arc circuit. The advantage in using an electric arc is readilyapparent from the .fact that the temperature which is above 5000" F. at one atmosphere and the plasma of an electric arc is great.

enough to evaporate most present-day materials. As' a result, the electric arc may accomplish drilling and cutting of materials which cannot beso-worked by any other conventional means. The primary difiiculty in utilizing electric are for producing a hole byevaporation is in the controlling of the location and the uniformity of the hole. This results from thearc often being 'wider than the hole desired to be drilled and additionally the arc cannot be accurately controlled and tends to slightly wander on the surface of the workpiece once the plasma is established entire surface. A further reason forthis lack of control is that the arc is not a regular shaped beam, sow-speak,

but rather is irregular in its form and thus thehoie-drilled i. will have such a characteristic of the irregularity;

The optical maser or commonly referred to iaser'provides a means for producing and amplifying coherent- The solid lasers such as the ruby laser provide greater power and short pulse durations, their work function is still too small for many industrial applications. Thus,.-the laser has. been utilizedfor theactive drilling of small holes in'thin-metal films This results'from the fact that in tdays technology the theoretical power, previously re ferred to as watts percmfi. cannot beachieved. Generally'the output of the available laser of today is-up to the order of three joules of work. Thus, in order for'the pulsed laser to be used to drill a hole of sufiicient depth, an exceedingly high number of individual pulses would be required to accomplish this result and thejob would be extremely time consuming.

Thus, an object of this invention is to' provide a method and apparatus for accurately controlling the output and location of an electrical are on the surface of a workpiece; 1

Another object of this-invention is'to provide higher work on a workpiece than that realized from the utilization of either an electrical are or optical laser.

Still another object of this invention is to provide a novel method and apparatus for the machining of ..ma-

terials.

3,214,553 Patented Get. 26,. 1-965 ice it is believed the above and other objectswil l become-- apparent from the following detailed description in which:

FIGS.. la-c, represent the three stages in the forma- FIG. 2 is a diagrammatic view of anelectric arc' and plot of voltage drop,

FIG. '3 is a pictorial view of the-apparatus. used in util-izing the novel rnethod-oithis-invention.

a hot. plasma. at the point.- wherethe-hole is tobe drilled. Theme is established after the plasma is formed by the laser and provides the largeworkwenergy required "to evaporate a. larger or deeper-hole.-

' To better understand theinvention', a description of the phenomenon of producing an arc without-the presence of a laser beam between. two electrodes will lac-discussed herein withreference particularly to FIG. I, a-c.

trative purposes. It is called thesparkingnstage.

As seenin FIG. la, the firststage of the arcing is seen. This is normally called the corona of streaming stage. This is. the phenomenon of gas breakdown when the electrical stresses atthe surface of the electrodes exceed the values necessary to produce-ionization in the surrounding gas. It is the condition preceding sparking that i's-seen normally,- the greaterdegree of streaming iSOl'l the cathode while a smaller amount is found on theanode. As

described herein, the cathode will normally be-the workpiece whilethemodels the electrodedirected at thework piece. This is not necessary but is being-used for illus- The second stage is seen in FIG. 1b.. At this point there is an unstableand discontinuous occurrence'marking the'transi tion from onemore-or less stable'condition occurring between the-electrodes in the gas toanother one. At the sparking stage a conducthig path is formed, completely bridging the gap. Additionally, an eflicient source ofsec- V ondary emission must beprovided at the cathode. The

conductivity produced must have been suffici'ent to at least dischargethe electrode for the-spark to said tohave passed. Forzair tlie minimum'sparking condition is norr mally .2775 volts. .Similarvalues :hold 'for other gases. .It should be pointed out that ahiscrequirement 'ofvoltage Yisfor a spark'to occur without'touching'the electrodes.

The third stage 10f creating anelectrical *arc is shown-in FIG. 16. This is *the arcing stage. An arcingis a'discharge whose cathode'mechanism depends largely on thermionic-emission. To: furtherdescribe the are; reference is now made 'tosthcsregion adiacent-the-anode. .In this area .thermionic emission is created due-largely to collisions of high velocity electrons. 1 Due to the collisions of these electrons therefisadditionally-produced positive ions which though relatively few in number-mustbe present in order 'tosustain thearc.

Additionally, a negative space charge is built up surrounding the anode whichcharge is due' to the secondary emission of electrons from the anode.

These electrons from the secondary-emission are caused by the bombardment on the surface :of thezanode of-the higher velocity electrons; The cathode is' the. largest source of thewthermionic emission, which is generally much greater than that-found-in the-anode. Thisthermionic emission-is due largely to bombardment of thesurface oithe cathode bypositiveions. Ibis bombardment is mostly from ions of a gas :and is generally not created by the positive .ions from the anode. Inthe gas column itself, the ionization is .due largely to collision between neutral configurations at elevated temperatures. Electrons in the arc'ionize molecules-indirectly by raisingthe temperature .of individual atoms of molecules. The rtem- .s,214.,'ses

3 perature in the arc column is dependent on the gas species and is independent of the current flowing in the are since this process is essentially in equilibrium.

To explain the function of the laser, a discussion of the output thereof should be described. The focused power output of the laser theoretically is where r=radius of objective d=diameter of the objective f=focal length of the objective A==wavelength I (r)=intensity of radiation I =intensity at workpiece Assuming the coherent light output fills the objective, the

focused light pattern is:

Thus, the intensity (I is:

- A p 1 fr where A=area of the objective P=power in the light beam out of the laser In the herein invention the focal point of the laser is directed to the point on the workpiece or cathode desired to be drilled. Thus, the gas at this focal point is ionized by the laser output due to thethermionic emission ofthe workpiece. In effect one might visualize a sheet of material where the electrical conductivity is uniformly low at all points except at the focal point of the laser where it is high. Since electron flow will seek the path of least resistance, an arc should always tend to establish itself between the plasma point and'the anode assuming a uniform electrical field existing over the sheet. It is this effect which serves to guide the output of the anode and the arc itself to agiven point on the surface of the workpiece, thus carefully controlling and pinpointing the arc.

For purposes of illustration of the. significance of the invention, attention is directed to FIG. 2. The model chosen for demonstrating the properties of the electric arc is a thermionic cathode emitter similar to a gas field arc tube where the gas would be-air at one atmosphere pressure and with local plasma at the focal point of the laser system emitter from the cathode. A typical are carrying 4 the arc adjacent the tip of the cathode to the body of the cathode itself. In the case of the utilization of the laser, the gas at the focal point on the cathode is already ionized by the laser output. Thus, V or the voltage drop across the cathode can be expected to be lower than normally encounteredin gas discharge tubes, is on the order of 5 to volts. Thus, in general it may be stated that substitution of the normal potential fall in part or wholly by use of an external thermionic source, that is'the laser, changes the energy balance of the electric arc. Two major effects result from this: (I) More of the arc electrical power is converted into increased available work energy. In other words, without the laser a significant portion of the electrical power in the arc is diverted to create the necessary thermionic emission on the surface of the cathode as shown in FIG. 10. Now that this thermionic emission comes from the laser rather than the arc, the electrical power in eight amperes with carbon electrodes 1 and 2 spaced about 4 mm. apart is disclosed in FIG. 2. The figure depicts the case of a cold cathode emitter. For a hot cathode emitter the voltage drop across the cathode is much lower, being approximately the ionization potential of the molecules;

As seen from the graph in the figure, the total voltage drop across the arc is volts. The cathode fall, V is about 15-20 volts as shown. The anode fall, V is not of any moment for this discussion and is shown for illustration only. The cathode fall is a voltage drop from a point in the arc may be utilized strictly for work purposes and not wasted on establishing thermionic emission. (2) The temperature gradient or heat loss at the work is lessened. An additional etfect obtained through the utilization of a laser in combination with the arc is that the experimental results obtained indicate that the focus laser emission tends to constrict or narrow the are plasma at the focal point of a laser. As a result, the precise location and size of a hole to be drilled is very accurately'determined and controlled. Additionally, because of this constricting effect, temperatures of the are at the local point of the laser should be further increased since all the plasma energy is restricted to a more narrow area and not dispersed over the workpiece. This effect and the previous effects enumerated all tend to increase the work potential of the elec tric arc.

Toillustrate the principle of this invention, reference is 7 now had to the apparatus as shown in FIG. 3. A base plate 12 serves to support the various items utilized in performing the invention although the various means may be separately supported. A housing 13 containing the ruby laser utilized is provided having a lead 14 from a capacitor bank (not shown) to supply the power and a 'second line 15 to trigger the laser. The output of the laser is directed through a focusing lens 15 towards the workpiece 16 mounted on a support plate 17. It is to be noted thatthe workpiece is supported at an inclined angle to the axis of the laser beam and is perpendicular to the electrode 18 utilized. However, this is not critical and the laser beam and electrode may be in any relative feasible position. It is pointed out that the laser beam controls the direction of the hole drilled with the are following the plasma generated. In the particular case illustrated, the hole drilled would be inclined at'an angle through the piece 16 in a line with the laser beam. The electrode 18 is positioned and controlledj by movable clamp 19 sothat'its angle may be readily changed as needed. Power is supplied to the electrode 18 through the lead 21 while the line 22 maintains the potential on the workpiece 16.' The leads 21 and 22 go to a power source not shown and are connected to this source so as to maintain the workpiece as a cathode and electrode 18 as an anode. The clamp member 19 in addition to permitting rotation of the electrode 18 also permits movement of the electrode closer to or farther from the workpiece 16.

The temperature of an electric arc is difiicult to establish. For example, gas pressure, molecular species present in the gas, partial velocities, frequency of collisions, must be considered and generally they may only be estimated. 1 cm? of nitrogen weighs 1.25 ll)- grams at 0 C. and 1 atm. The energy level required to ionize the nitrogen atom-to its first energy level is 15.65 ev. or 2.4x 10' joules. Considering the energy required 1 to ionize all nitrogen atoms in a gas column 1 cm. at 1 atm. to their first energy level requires 1296 joules, it is reasonable to assume that the plasma temperature is well above 5000 F. The boiling point of iron is 4272 F. at this temperature, thermionic emission at 1 atm. and the melting points of other higher temperature elements suchv as ruthenium and osmium are less; therefore the temperature of plasmas from art-electric arc should be suiiicient to melt over vaporized all materials encountered inmanufacturing processes.

The breakdown voltage of air is approximately to 23' volts per mil at 1 atm..; therefore if one assumes a. 0.5 inch separation between the sheet to be drilled (cathode) and the anode (electrode) thev breakdown potential should; be 11.5 kv.

The. ruby laser utilizeddelivcred approximately-none ioule of light energy concentrated in an area about .020 inch diameter' at a-wavelength of" .7 micron. This is sufiicient energy to vaporize material at its surface and produce thermionic emission. A first series of tests were conducted with arninimum sparking potential of 7 kv. which was. required to break down an electrical gap 8 mm. wide and the laser was used to trigger the arc.

When the gap was reduced to 4 mm. the potential was reduced to 6 volts. Again the lasersuccesstully triggered the arc. From the experiments conducted, it was found that the sparking potential versus the gap width was not linear. Thus, it is concluded that the arc is riggered bythe plasma generated by the laser. For example, 15' lav. were required without the laser to break down an air gap 8 mm. in width; whereas it took only 7 .kv. with the laser as previously mentioned. Additional tests disclose that. no are triggered occurs when the electrode is placed at' a position so as not to intercept the plasma at the: reduced electrode potentials.

In the experiments conducted the target was at a negative potential with respect to theelectrode. The electrode was made of drill rod steel sharpened to a point. The

ablation of the electrode point was. evidenced; The" of about 7000 kwjin. comparing favorably with suc-' cessful electron beam welding.

The machining potential was demonstrated bydrilling a hole about .015 inch in a. diameter and .068 inch deep in an aluminum alloy sheet. This hole was drilled insix milliseconds. burst" which. amounted to about .011: inch of' metal. removed with each firing; Laser. burst. alone had negligible affect; With the are alone there was also -a negligible afiect. For these. experiments the electrode was separated approximately 1' mm; from. the workpiece.

Generally, the optimum power output obtained. from the: laserwas at: a pulse time of nominally 1- millisecond. There is not a. continuous power output over this time period but rather the 1. millisecond represents the total time of output fromthe laser during the pulse;. In carrying out the processof this invention it should be apparent that. a delay between the initiation of. the pulse frorn the laser and the triggering of the arc isnecessitated in order for the plasma to be generated by the laser and affect. the arc. Normally the delay is of a; very short period of time andwas not capable of measurement. with theap paratus used for the experiments. This delay' would normally be on the order of from between .5 and 1 microsecond. The are is pulsed through. a capacitor. battle (not. shown) connected tothe electrode. This bank is constructed such that its discharge time is less than the laser pulse length; However, it should be established that the delay can vary considerably depending upon the material worked upon, the power source and other factors. The controlling criteria for such delay probably resides It" was further This restricted.

ence of the plasma generated by the. laser.

in the duration ofthe plasma generatedv on the workpiece through the utilization of the laser. In other words. the arc must be created and extinguished duringthe exist- Thus,. the: delay between the. triggering oifthe are. from: that'of the ignition of the .lasershould be within: the periodv of time which plasma exists on-the workpiece.

The invention is described relative toa pulse lasersince only such is currently available. As technology advances and a continuous-output laser-of s-ufiicient' power becomesavailable, the invention contemplates utilization of a cou tinuousarc in combination with the. laser.

The laser device utilized in this invention isconven' tional: in the art. its construction and components have been discussed at length in the literature. The particular laser device utilized in this description had a ruby crystal measuringone-fourth; inch in- .diameter by three-and-onefourth inches in length. flash lamp was supplied" which was designed for use up to 800 joules. The cavity-is'a.

- silvered. and polished. cylinder: The output wavelength.

is 6943 angstroms. The laser. tires on: voltages from" 500 to 2000 voltsproducing'output energy levels of' one. joule. uncooled and three. joules when cooled with liquid nitrogen;

A. particular advantage of the describedv method is that itisindependent of gas pressure; By: the adjustment of electrical parameters, the process may be made to work at increased or decreased gas pressure relatively easily and without any practical limits.

Additional application of the process described is that it. may be utilizedv as a remote control device. Inthis application it may be used as an ignitor for very high voltage are gaps by placing the low-voltage, high current; electrode in the normal gap area. and remotely triggering. this are to produce quantities of ionized gas to' break down the larger gap; Thus, it can. beseen: that: the. pros ess maybe used as a. control method for: any application that requires timed generation of electrical-ionized mole-- oules; Additionally, the method may be utilized to remotely control work such as invacuum; tube manufactur-- ing. By placing two metal pieces in close proximity to each other a glass envelope and applying an externalelectrical potential, the; location and control of the. weld would'be accomplishedby pulsing an external laser whose 1 light beams penetratethe glass envelope and focus on the.

pointtov be welded;

Additionally, it should be established. that the inverttion. described. has wider applicability than. drilling. holes. For exa-mple,.with acontinuous laser or onethatmay be pul'sed-f with great'rapidity the: invention would'haveuse in.

the field of cutting of imaterials-andofi Welding; When welding, the electrode may be consumable or, alternatively, the weld material-1 may come from; an outside source.

Although the. invention has. been described and illustrated in detail, it is to be clearly understood that the: sameis' by wayof illustration: and example only and. is notto be takenby'way'ofilimitatiomthe spirit'andzscope ofi thisinvention being limited; only bythetermsr-of. the appended.- claiins.

Itcl'aim:

1.. A method; of. working; a material comprising:

providingv a laser beam producing means,-

tocusing the laser' output to a desired point on saidv material thereby generating plasma at said. point,.

providing an electrode in close proximity to'said mate rial, maintaining an electrical potential between 'said electrode and said material causing an electrical; arc: to be created between said. electrode and. said point, whereby said laser output: continuously con-- trols said arc. throughout the work. performed. 2. Av method of working a material comprising: providing a laser beam producing element, focusing the laser output to a desired point on said material thereby generating plasma at said point,

7 providing an electrode in close proximity to said material, maintaining an electrical potential between said electrade and said material causing an electrical arc to be created between said electrode and said point subsequent to the creation of said plasma, whereby said laser output continuously controls said are throughout the work performed. I 3. The method of claim 2 wherein the delay interval between the creation of said plasma andthe causingof said electrical arc does not exceed 1 microsecond.

4. A method for accurately controlling the position of an electrical are comprising:

creating a laser beam and, continuously focusing said laser to a point on a mate- 5 rial where it is desired to strike said electrical arc to maintain and stabilize said arc.

References Cited by the Examiner FOREIGN PATENTS 10 850,428 10/60 Great Britain.

RICHARD M. WOOD, Primary Examiner. 

4. A METHOD FOR ACCURATELY CONTROLLING THE POSITION OF AN ELECTRICAL ARC COMPRISING: CREATING A LASER BEAM AND, CONTINUOUSLY FOCUSING SAID LASER TO A POINT ON A MATERIAL WHERE IT IS DESIRED TO STRIKE SAID ELECTRICAL ARC TO MAINTAIN AND STABILIZE SAID ARC. 